Industrial Energy Efficiency Accelerator - Guide to the laundries sector Each year the UK industrial laundries sector processes approximately 743,651 tonnes of mainly hotel linen and towels, work wear and linen and garments for the health sector across 134 sites. The energy required to process the product is 1,254 GWh, equivalent to emissions of approximately 281,500 tonnes of CO2 per year (tCO2). Executive summary The Carbon Trust Industrial Energy Efficiency Accelerator (IEEA) was launched in 2008 with the objective to identify and accelerate the take up of innovations by industry to reduce CO2 emissions. The programme is split into three stages, Investigation and Solution Identification (Stage 1), Implementation (Stage 2) and Replication (Stage 3). This report presents the findings from Stage 1 of the IEEA for the laundries sector. Each year the UK laundries sector processes approximately 743,651 tonnes of mainly hotel linen and towels, work wear and linen and garments for the health sector across 134 sites. To deal with this requires an energy consumption of 1,254 GWh, which equates to emissions of approximately 281,500 tonnes of CO2 per year (tCO2) 1 . The sector has made significant improvements in its energy performance between 2008 and 2010, with an improvement of 7% being made against its Climate Change Agreement targets. The Carbon trust has been working closely with the sector in 2010 and 2011 to understand the energy use in the laundry process and then to identify opportunities capable of making a step change in energy efficiency. The initial engagement and investigation sought to identify potential innovative opportunities across the laundry through the washing, drying and finishing processes. The monitoring strategy was devised to provide understanding of the separate laundry processes and provide an insight to how they were related and what the savings potential was. This programme was supplemented by engaging with the sector and its supply chain to develop a prioritised list of opportunities for carbon reduction. The overall maximum carbon saving potential for the sector through both good practice actions and future innovation is estimated to be 26% or 74,500 tCO2/yr. The good practice element of this, which includes measures that are well documented, mature and can be implemented by the sector without future Carbon Trust intervention, can deliver around 9% carbon savings (26,000 tonnes pa). Other more innovative opportunities offer the remaining carbon saving potential identified (48,000 tonnes pa). The level of carbon savings that are actually achieved will depend on how many measures the sector implements. 1 Data supplied by the Textile Services Association for the year to September 2010
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Industrial Energy Efficiency Accelerator - Guide to the laundries sector Each year the UK industrial laundries sector processes approximately 743,651 tonnes of mainly hotel linen and towels, work wear and linen and garments for the health sector across 134 sites. The energy required to process the product is 1,254 GWh, equivalent to emissions of approximately 281,500 tonnes of CO2 per year (tCO2).
Executive summary The Carbon Trust Industrial Energy Efficiency Accelerator (IEEA) was launched in 2008 with the objective to
identify and accelerate the take up of innovations by industry to reduce CO2 emissions. The programme is split
into three stages, Investigation and Solution Identification (Stage 1), Implementation (Stage 2) and Replication
(Stage 3). This report presents the findings from Stage 1 of the IEEA for the laundries sector.
Each year the UK laundries sector processes approximately 743,651 tonnes of mainly hotel linen and towels,
work wear and linen and garments for the health sector across 134 sites. To deal with this requires an energy
consumption of 1,254 GWh, which equates to emissions of approximately 281,500 tonnes of CO2 per year
(tCO2)1.
The sector has made significant improvements in its energy performance between 2008 and 2010, with an
improvement of 7% being made against its Climate Change Agreement targets.
The Carbon trust has been working closely with the sector in 2010 and 2011 to understand the energy use in the
laundry process and then to identify opportunities capable of making a step change in energy efficiency. The
initial engagement and investigation sought to identify potential innovative opportunities across the laundry
through the washing, drying and finishing processes.
The monitoring strategy was devised to provide understanding of the separate laundry processes and provide an
insight to how they were related and what the savings potential was. This programme was supplemented by
engaging with the sector and its supply chain to develop a prioritised list of opportunities for carbon reduction.
The overall maximum carbon saving potential for the sector through both good practice actions and future
innovation is estimated to be 26% or 74,500 tCO2/yr. The good practice element of this, which includes
measures that are well documented, mature and can be implemented by the sector without future Carbon Trust
intervention, can deliver around 9% carbon savings (26,000 tonnes pa). Other more innovative opportunities offer
the remaining carbon saving potential identified (48,000 tonnes pa). The level of carbon savings that are actually
achieved will depend on how many measures the sector implements.
1 Data supplied by the Textile Services Association for the year to September 2010
Laundries Sector Guide 2
Innovative opportunities for significant carbon emission reduction applicable across the sector fall into six distinct
areas, which are shown below along with the cost to deploy each on a single trial site and the total sector level
savings possible assuming maximum sector-wide take up:
Table 1 Innovative Opportunities
Challenge Area
Demonstration
Project Cost
(£)
Sector Savings
Annual Carbon Dioxide
Savings
(tCO2)
Annual Cost Savings
(£)
Industry process
Model
£125,000 8,433 £1,130,000
Heat management
incorporating CHP
£500,000k - £800,000k 14,600 £934,000
Polyester based towels £50,000 - £100,000 10,000 £1,683,000
Up rating low grade
heat using MVR
£100,000 - £200,000 5,600 £1,000,000
Retrofit temperature
and humidity controls
£50,000 -£100,000 6,480 £210,000
Diamond electrode
(low temperature)
washing
£150,000 8,138 £1,200,000
The next steps are for the project teams to be put together and to either work as a partnership or secure third
party funding to help provide the resource and support to fully understand and exploit the potential offered by
these innovations.
Laundries Sector Guide 3
Table of contents Executive summary .................................................................................................. 1
1 Background to Industrial Energy Efficiency Accelerator ................................. 5
The development of an industry process model was one of the favoured options with the group able to see the
benefits of such a model and how it could be applied within their sector and organisation to help identify and
spread best practice, encourage innovation and to help further understand and explore the variances and
parameters of the laundry process.
With the laundry process basically having three sub processes of washing, drying and finishing there are a lot of
factors that can influence performance and one of the benefits of a model would be the ability to understand what
would happen to the drying and finishing processes if the wash temperature was reduced.
The model would also allow for data to be stored from the various participating sites to enable accurate
benchmarking data to be available for all parts of the process and not just the laundry operation as a whole.
Having access to this level of data would allow individual operations to be benchmarked and best practice or
technological innovation to be identified.
Any such model would also help foster innovation, where different innovation scenarios could be played out to
gain an initial view of their complexity and impact to help understand their viability prior to any further investment.
It is anticipated that any such model would have applications across the sector, for laundries of all sizes, with
differing costs to gather the requisite data from the sites to fuel the model. The model would give more
representative results as more laundries participate in its use and contribute to its data bank.
Laundries Sector Guide 47
There would also be costs involved in developing the model initially and ensuring it gives a representative view of
the process and can cope with all the variables from differing technologies to different fabrics.
Industry Process Model
Technology maturity and need for support
The development of industry process models has been carried out in other sectors. The key issue for the sector is to gather enough data to be able to develop and test the model and establish suitable benchmarks for the process and its various parts. The outputs delivered by the model would need to be delivered in a way that the sector or individual companies could work with. Trials on the impact of modelling should be carried out to determine its effectiveness and the savings that can be expected and how replicable it could be.
Overview of Next Stage
A demonstration project should be carried out in the UK to determine the practicalities of this project (particularly gathering the large amount of detailed data), the usefulness of any outputs and the savings potential.
Cost of demonstration project and possible structure
The estimated cost for running a demonstration project at commercial scale would be expected to be in the region of £125,000.
Typical activities to be completed for a demonstration project would include:
Gathering of representative data to develop and prove model
Development of software to provide the model platform and site interface
Proving trials to provide credibility and assurance over models outputs
Develop useful reporting framework
Understand ease for replication and mass adoption
Promote findings from work
Annual Carbon saving potential
Maximum – 8,433 tCO2
Assuming an average reduction of 3% of current emissions.
Market penetration 50% in 10 years
Project persistence High – 10 years
Lifetime CO2 saving (based on 50% take-up over 10 years)
42,165 tCO2
Sector energy saving £1,13m per year
Cost of technology (once mature)
£20,000 average per site
Payback Average 2.5 years
Barriers to Adoption
The level of data collection required from laundries and its associated cost.
Creating widespread adoption of the model throughout the sector to develop a significant data set.
Developing a model which will keep pace with technology developments.
6.1.2 Heat management incorporating Combined Heat and Power
Advances in the technology of utilising the low grade heat generated by a CHP plant can now be applied to
laundries; this significantly improves the project economics and in certain parts of the market makes CHP a
viable option. This has been done successfully in laundries in mainland Europe.
The integration of a CHP with a laundry site would require a bespoke design in all cases. However the general
principals are;
Gas fired engine used as prime mover
Laundries Sector Guide 48
All electricity generated would be used on site
Steam would be generated by engine exhaust for use in ironers and finishers
Heat from engine cooling would be stored in a hot water accumulator which would supply energy to
continuous batch washers, washer extractors and to a dryer preheat system.
It is likely that the best sites for successful adoption of CHP would be the very largest sites with high utilisation.
There are 10 sites which process more than 14,000 tonnes a year in the sector. If CHP plants were installed at
these sites annual emissions savings of approximately 73,000 tonnes CO2 could be achieved.
The sector has showed interest in the potential energy savings that could be achieved but it will require
demonstration of a successful project at a UK laundry. A demonstration project could be undertaken by a CHP
supplier and a laundry site to prove the plant technical feasibility and economics. However the capital costs of
CHP plants installations are high, estimated at £750,000 for a suitable site. It may be possible to involve a
contract energy management provider in the demonstration project. They could arrange for capital financing of
the project and supply the expertise for operating the plant.
Combined Heat and Power (CHP)
Technology maturity and need for support
CHP is a mature technology in a number of sectors in the UK. It has also been applied successfully at a number of laundries in main land Europe, but has yet to be used at a UK site. The key issue for the sector is to establish whether CHP can be applied economically to a UK laundry. This would best be achieved through a demonstration project undertaken at a UK site. The demonstration project would need to be at a commercial scale and over sufficient period to demonstrate the benefits.
Overview of Next Stage
A demonstration project should be developed at a UK laundry at a commercial scale. This should focus on demonstrating that the technology is a suitable match for a UK laundry heat use profile and project economics. A suitable consortium for developing this opportunity would be a CHP supplier working with a contract energy management company and a suitable laundry company.
Cost of demonstration project and possible structure
The estimated cost for running a demonstration project at commercial scale would be expected to be in the region of £500,000 - £800,000 depending on the actual work to be undertaken. Typical activities to be completed for a demonstration project would include:
Assessment of current plant – to establish site heat loads and energy
utilisation profiles
Design and costing of CHP plant
Development of project monitoring strategy.
Operation to prove plant reliability and economics.
On-going operation to confirm plant performance over an extended period
Promote findings from work
Annual carbon saving potential
Maximum – 14,600 tCO2
Market penetration 50% in 10 years
Project persistence High – 10 years
Lifetime CO2 saving (based on 50% take-up over 10 years)
73,000
Sector energy saving £934,000 per year
Cost of technology (once mature)
£500,000 to £1,00,0000 (average £750,000)
Payback Average 4.0 years
Laundries Sector Guide 49
Combined Heat and Power (CHP)
Barriers to Adoption
You have already taken this out in your adoption model.
Forward energy price predictions for the UK may adversely affect project economics.
The supply chain may not put in sufficient market resources to exploit the developed technology.
It may prove difficult to raise the necessary capital for wide scale adoption.
6.1.3 Switch to polyester based towels
The processing of cotton towels through laundries is particularly energy intensive. This is primarily because the
thick cotton fabric absorbs a large amount of water during the washing process which then has to be driven off in
relatively inefficient tumble dryers. For some time fabric and towel manufacturers have been working on putting
polyester into the towel fabric weave reducing the weight and amount of water it absorbs. However most
laundered towels are used in the hotel industry and there has been some concern from this sector as to
perception of towels with polyester by guests. The workshop revealed significant support for the project if the
customer reservations could be overcome.
Towels make up approximately 40% of the product processed by the sector. It is anticipated that towels with
polyester could in principal be utilised by all towel laundries. If this was possible annual emission savings from
reduced thermal energy use are estimated at 10,000 tonnes CO2. These savings are based on towel with a 30%
reduction in weight over those in current wide spread use. Further energy savings in site electricity use are likely
since the lighter product will require less motive energy and higher plant utilisations per piece may be achieved.
These energy savings have not been quantified at this stage.
The development of a demonstration project incorporating extensive testing and market research should prove
the acceptability of the product change and overcome the key barriers and concerns.
Use of Polyester in Towels
Technology maturity and need for support
The increased use of polyester in towels has been looked at for a number of years. However there has always been a significant amount of resistance from the major laundry customers because the potential effect on end user experience. Trials need to be undertaken as part of a demonstration project to test this assertion, prove towel durability, and that energy savings can be achieved.
Overview of Next Stage
A demonstration project needs to be established to prove that new towel material is acceptable to customers and projected energy savings can be achieved. A suitable collaboration would be between a towel manufacturer, laundry and hotel customer.
Cost of demonstration project and possible structure
The estimated cost for running a demonstration project at commercial scale would be expected to be in the region of £50,000 - £100,000 depending on the actual work to be undertaken. Typical activities to be completed for a demonstration project would include:
Developing a suitable fabric and towel product. This is thought to have
been largely achieved already.
Designing suitable test programme for new towels in commercial laundry
Monitor energy savings achieved when processing new towels through
laundry.
Condition monitoring of towels during trials to assess durability.
Undertaking market research on suitability for customers and end users.
Promoting findings from work.
Annual carbon saving Maximum – 10,000 tCO2
Laundries Sector Guide 50
potential Have assumed towel will hold 30% less moisture, and assumed it will not affect the washing process, but will impact on the drying process with 30% less moisture to remove.
Market penetration 75% in 10 years
Project persistence High (towels will be replaced on regular basis as before, trials needed to assess new towel life)
Lifetime CO2 saving (based on 75 % take-up over 10 years)
50,000 tCO2
Sector energy saving £1,683,000 per year
Cost of technology (once mature)
New towels no more expensive
Payback N/A
Barriers to Adoption
The new towel material may prove to be unacceptable to customers and/or end users.
The projected energy savings are not achieved.
The new towels prove to be less durable.
6.1.4 Up rating low grade heat using mechanical vapour recompression (heat pumps)
It has been identified that significant quantities of heat are lost through laundry dryer and finisher/ ironer exhaust
ducts. It is generally been considered by the industry that the recovery of heat from these exhausts streams
would not be economic, primarily because;
There would be no suitable heat sink to recover the energy to because laundries generally have a surplus of
low grade heat.
The exhaust streams are at only moderate temperature
The complexity of heat recovery installation
The diversity of laundry plant
The monitoring results and sector feedback identified that these barriers may be overcome if the waste heat
could be upgraded to a higher temperature that would make its utilisation more effective. This could be most
effectively achieved by applying heat pump technology, which is already well established in other sectors such as
chemicals. Two types of heat pump technology could potential be utilised;
Closed Cycle Heat Pumps – A working fluid, totally isolated from the process stream, picks up heat from the
dryer or finisher exhaust and is then compressed to a higher pressure and temperature. It is then condensed
and gives up heat to the recovery stream.
Mechanical Vapour Recompression (MVR) – The exhaust stream itself would be compressed to a higher
pressure and temperature and then condensed to give off heat which would be recovered.
There is an additional electricity demand associated with the operation of the pump or compressor however the
coefficient of performance is high for this type of plant and far more heat energy can be recovered than electricity
expended. The recovered heat would most likely be used to preheat the drying or finishing process, but could be
used to generate hot water.
It is considered that this technology would be most successfully applied to larger laundries with higher utilisation.
These sites generate high quantities of waste heat over long operating hours. If the technology could be applied
to the 24 UK laundries with an annual production rate of over 8,000 tonnes a year, annual emission savings are
estimated at 5,600 tonnes of CO2. The average payback on capital would be approximately 3.5 years.
A key barrier to delivering the project across the sector is that the technology has yet to be used successfully in
laundries. This concern could be overcome if a commercial scale demonstration project was undertaken on a
Laundries Sector Guide 51
suitable plant. This could be undertaken as a collaborative project between a laundry company and technology
supplier. Once the technology was proven with the sector it could be developed for adoption by other laundry
sites.
Upgrade and Recover Waste Heat Using Heat Pumps
Technology maturity and development needs.
The application of heat pump/ MVR technologies is well established in other sectors e.g. chemicals. The key issue for the laundry sector is to establish suitable technologies and confirm the financial benefit and carbon savings that can be delivered. It is recommended that projects would need to be at a commercial scale so that outputs can be considered representative to the industry.
Overview of Next Stage
A demonstration project should be established to determine the benefit of recovering upgraded waste heat in the sector. This would focus proving that the technology can work in a laundry and that the waste heat can be usefully recovered. A suitable consortium to take this forward would include a laundry company and technology supplier
Cost of demonstration project and possible structure
The estimated cost for running a demonstration project at commercial scale would be expected to be in the region of £100,000 - £200,000 depending on the actual work to be undertaken. Typical activities to be completed for a demonstration project would include:
Assessment of current oven installations to establish equipment
specification and operating practices
Designing and costing of proposed heat pump and heat recovery
installation.
Development of monitoring methodology and meter installation
Commissioning and phase 1 operation to optimise performance and
learning from optimisation
On-going operation to confirm performance both in energy saving,
operating reliability etc.
Defining of solution and process to roll out to other sites and/or sector
Promoting findings from work.
Annual Carbon saving potential
Maximum – 5,600 tCO2
Assumed it is applicable to sites >8000tonnes production and have used a conservative COP for the MVR of 5
Market penetration 50% in 10 years
Project persistence High – 10 years
Lifetime CO2 saving (based on 50% take-up over 10 years)
28,000 tCO2
Sector energy saving £1.0m per year - maximum
Cost of technology (once mature)
£100,000 – £200,000 (average £150,000)
Payback Average 3.5 years
Barriers to Adoption
The technology may prove to be too expensive to give a satisfactory payback except for plants that are very highly utilised.
It may prove to be difficult to utilise recovered heat effectively.
The supply chain may not put in sufficient market resources to exploit the developed technology.
Laundries Sector Guide 52
6.1.5 Retrofitting temperature and humidity control of tumble dryers
The proposition to explore the impact of retrofitting temperature and humidity control to tumble dryers also
received support. The benefit of additional control would enable the drying process to be run at peak
optimisation, prevent any “over drying” and ensure only the required amount of energy is put into the dryers to
achieve the required results.
The fitting of additional control would lead to a reduction in energy usage; it has been assumed that it will save
8% of the dryer‟s energy consumption and lead to shorter cycle times.
Currently drying is controlled by varying the time spent at a fixed temperature which is set by experience; the use
of advanced controls will become more advantageous when mixed loads are sent through the dryer as the cycle
time and thus thermal requirement will vary.
Within the laundry sector new dryers are entering the market already fitted with this type of control, so it has been
assumed that only half the dryers used in the sector will have the need or potential to have additional control
fitted.
The cost of the required equipment and installation has been estimated at £5,000 per installation.
Temperature and Humidity Controls
Technology maturity and need for support
The technology for controlling the drying process using temperature and humidity and retrofitting into existing tumble dryers exists and does happen. The need for support here is to prove the business case for installing these controls and thoroughly understanding the impact it has across all laundry types.
The savings that can be generated need to be understood for their use with laundries processing similar loads and those processing a variety of different load types.
Overview of Next Stage
A demonstration project should be established to estimate the benefit of these controls. The project should focus on ease of installation, savings and any increased maintenance costs. The impact of the controls on similar load types should also be understood.
Cost of demonstration project and possible structure
The estimated cost for running a demonstration project at commercial scale would be expected to be in the region of £50,000 - £100,000 depending on the actual work to be undertaken. Typical activities to be completed for a demonstration project would include:
Testing for prolonged periods on laundries processing similar loads and those processing a variety of loads. Loads may vary by weight, fabric and item type.
Substantial metering of the drying process to allow savings to be
calculated would need to be completed
Testing to understand any perceived impact on the rest of the laundry
process (finishing)
Understanding the ease for replication and adoption
Promoting findings from work
Annual Carbon saving potential
Maximum –1,296 tCO2
Have assumed 15% of energy used on dryers, with 50% of the dryers in the sector eligible for retrofitting and have assumed an 8% saving.
Market penetration 50% in 10 years
Project persistence High – 10 years
Lifetime CO2 saving (based on 50% take-up over 10 years)
6,480 tCO2
Laundries Sector Guide 53
Sector energy saving £210,000
Cost of technology (once mature)
£5,000 per installation (£1.3 m for the sector)
Payback Average 6.5 years
Barriers to Adoption
The laundry sector processes a large number of similar loads and it is whether or not a saving over timed saving can be made.
New tumble dryers entering the market will have this technology already fitted.
Can it be retrofitted easily into the control mechanism of all tumble dryers?
6.1.6 Diamond electrode washing
This can be used for both effluent treatment or cold water washing and disinfection. The principal process, is the
oxidation of a proprietary mix of simple electrolytes at the surface of the anode; secondary reactions generate
more stable intermediates such as peroxide, hypochlorite and ozone, which as well as cleaning at ambient
temperatures are able to attack a broad range of bacteria and viruses.
Initial trials of this technology have shown that washing at 25 C is possible, with initial benefits showing
Reduced Energy Costs
Reduced Chemical costs
Reduced Fibre Damage
Reduced Water Usage
Reduced Effluent Charges
This is new technology to the laundries sector and needs further testing to prove what is currently being trialled
and ensure it can be operated across the different types of laundry.
For the purposes of this report the business case has been developed comparing the installation of this
technology in laundries with and without heat recovery on their wash process. A rudimentary analysis of
returned sector questionnaires indicate that 80% of the sector has heat recovery installed, it has also been
assumed that this technology is suitable for workwear and flatwear only and have excluded any health/hospital
figures from this calculation. (It is envisaged that this technology will be suitable for both health and hospital
goods due to the disinfection effect produced).
For sites with good heat recovery systems, the energy savings will mainly come from the removal of the need for
a heat recovery system so significant savings can be made by removing the motive power needed to operate
these systems.
Diamond Electrode Washing
Technology maturity and need for support
Diamond electrode technology is new to the laundry sector, the process needs testing and the results evaluating for a variety of laundry types to enable an assessment of its repeatability, impact on the product and the savings that can be generated. This should be done on washer extractors and continuous tunnel washers (CTW‟s), with comprehensive metering in place to fully understand the technologies potential.
Overview of Next Stage
The technology is new to the laundry sector rand proving that is works is one obvious factor. The impact on fabrics and the rest of the process should be understood; the demonstration project should cover tunnel washers and washer extractors and should also evaluate performance in flatwear and workwear operations.
Cost of demonstration The estimated cost for running a demonstration project at commercial scale
Laundries Sector Guide 54
project and possible structure
would be expected to be in the region of £150,000 depending on the actual work to be undertaken. Typical activities to be completed for a demonstration project would include:
Testing for prolonged periods on washer extractor and Continuous
Tunnel Washer processes.
Testing on flatwear, workwear and hospital sites
Substantial metering of the wash process to allow savings to be
calculated
Testing to understand impact on the rest of the laundry process (drying
and finishing)
Analysing the effect of process on differing fabrics and their lifespan
Understanding ease for replication and adoption
Promoting findings from work
Annual Carbon saving potential
Maximum –8,138 tCO2
Assumed wash at 25 C and that 80% of sector will have heat recovery on their wash process
Market penetration 50% in 10 years
Project persistence High – 10 years
Lifetime CO2 saving (based on 50% take-up over 10 years)
40,690 tCO2
Sector energy saving £1.2m
Cost of technology (once mature)
£20,000 -£50,000 per installation
Payback Average 2.90 years (on purely energy only, savings from reduced use of chemicals, lower water and effluent charges have not been taken into account).
Barriers to Adoption
The technology is new and unproven to the sector which may delay take up
Initial capital cost may prohibit some of the smaller laundries.
The impact it has on sites with full heat recovery need to be understood.
Laundries Sector Guide 55
7…Next steps
The next step for the laundry sector is to consider collaboration. With Stage 2 funding no longer guaranteed the
sector and its supply chain must work together in order to form project teams to explore the potential of these
opportunities, co-ordinating and promoting this is maybe something the Textile Services Association should take
the lead on.
Regular dialogue should be maintained with the Carbon Trust to be kept aware of any possible funding streams
to assist in the development of these opportunities.
Small laundry Carbon Trust opportunities site survey (report extract)
Priority: Recommendations
Estimated annual savings
Estimated
cost (£)
Payback
period
(years)
Calculations & assumptions
(£) CO2
(tonnes) (kWh)
1
Design and implement an Energy
Management Policy applicable across the
business
2,500 20 90,000 2,000 0.8 This is assumed to save approx. 5% energy cost, typical from previous similar models
£51090 x 0.05 = £2554 (rounded to £2500)
2
Generate a broad awareness of staff,
customers and neighbours of the commitment
to carbon reduction
0 0 0 0 0 This is fundamental to the success of 1 above and the costs/benefits are included therein.
3
Implement management controls for
processing, distribution and stock
management by monitoring and targeting
across the operation
2,500 20 90,000 1,000 0.4
An assumption only, to achieve 5% reduction in energy cost across the business with un-quantified benefits in all areas.
£51090 x 0.05 = £2554
4
Carry out a lighting survey and install low
energy lighting to improve the quality and
safety within all sections
1,200 8 14,000 5,000 4.2
An estimated cost which will have a relatively long payback term, but with immediate operational benefits. Expert survey and quotation required for high bay and operator specific lighting to replace currently poorly located aged fluorescent tubes.
25% reduction on present estimated consumption of 14000 kW is assumed on the basis of previous factory lighting surveys.
5
Survey the steam boiler controls, feed tank,
blow-down, steam distribution system and
condensate return; implement a steam trap
survey regime. Renew pipe lagging where
required.
5,000 42 199,000 4,000 0.8
A comprehensive survey and implementation will save > 10% in total energy for a relatively modest initial investment of £4k and subsequent annual service/replacement cost of £1k This will pay back within one year. The operating steam pressure is only 6 bar which is low compared to industry norm, but to change would be a major cost.
6
Design and implement condensate heat
recovery for closed circuit benefit or to pre-
heat process water
1,500 12 59,000 6,000 4
This initiative links to 5 above. The useful heat returned may be used to pre-heat boiler make up water and contribute to the savings identified. Alternatively, pre-heating of process water would provide additional benefits of reducing wash process cycle time and providing a more efficient transfer of the useful heat. A calorifier system would also provide a hot water heating source for the current redundant central heating system. For the latter a modest 3% energy saving is assumed.
TOTAL − 127,00 102 452,000 18,000 1.42 −
Laundries Sector Guide 59
Medium laundry Carbon Trust opportunities survey (report extracts) including detailed recommendations which were provided as an additional part of the
consultative survey.
Priority: Recommendations
Estimated annual savings
Estimated
cost (£)
Payback
period
(years)
Calculations & assumptions
(£) CO2
(tonnes) (kWh)
1 Monitoring and targeting 12,694 73.6 343,653 1,000 0.08
This is essential to meet the requirements of the CCL exemption initiative. A target saving of 7.5% on kWh/tonne consumption between Dec 09 and Nov 10 compared with the 08/09 base line is required to be achieved. M&T in principle will achieve a 2% saving at minimal £1,000 cost which will cover training and administration.
2
Boiler
management/condensate
heat recovery
40,560 231.6 1,258,937 75,000 1.9 The installation of a FREME condensate return system will produce a minimum 8% saving based upon information from model installations. See further detail below.
3 Steam distribution 5,071 28.9 157,367 15,000 2.9
The steam distribution and condensate return circuitry was closely examined during the survey. Pipe sizing was deemed correct for the individual equipment demand and previous modifications to generate a defined ring circuit had improved distribution. A further modification to create a ring supply to and return from the Workwear section, tumblers and space heaters is recommended and detailed herein, saving approx. 1% in gas consumption alone.
This proposal is taken alone as an energy saving initiative and is based upon sound model data, however the costs are estimated. Effluent recycling which has only water saving attributes should be considered in conjunction with this proposal and such will improve the overall benefit.
TOTAL − 93,325 534.1 2,846,913 211,000 2.3 −
Laundries Sector Guide 60
Appendix B: Sector survey
IEEA Laundries Sector – Questionnaire
Company Name:
Questionnaire Completed by: Email:
Date:
Question 1: State of energy efficiency
How energy efficient do you consider your operation?
Is there scope for improvement? Yes / No
Are there specific areas of your operation which have the greatest potential for energy saving?
Yes / No
If yes please give further detail:
What are the barriers to your organisation becoming more energy efficient?
What payback period do you accept for energy saving projects and has this changed over the last 5 years?
Question 2: Monitoring and Targeting / Metering
Do you have an Energy Monitoring and Targeting system? Yes / No
Have you benchmarked your process against competitors or an industry standard?
Yes / No
Question 3 : Energy Efficient Technologies
Current energy efficient
technologies available
to sector
Please complete the table below, by indicting on the bar your organisations percentage uptake of the technologies identified (100% means that nothing is left to do, with 0% meaning it has not been implemented at all); and please include any additional technologies you have implemented, are planned, have assessed and rejected or have identified but not yet exploited. If the technology is not relevant to you then please leave the bar blank.
Variable speed drives
(VSD),
Energy efficient motors
0% 50% 100%
0% 50% 100%
Laundries Sector Guide 61
Low temperature washing
Product classification,
weighing and sorting
Renewables (e.g. Wind
turbines, solar technology,
biomass)
Improved process control
Use of temperature and/or
humidity control within the
drying process
Finishing process
operated fully
loaded/covered
Use of VSD compressors
Improved burner
technology
Heat recovery from wash
process
Heat recovery from drying process
Heat recovery from finishing process
Adoption of LED lighting
Flash steam recovery
Hydro-extraction press optimisation
Additional Identified Technologies
Technology Comment
Question 4 : Potential for CHP
Has CHP been installed at your site? Yes / No
If “No”, what were the restricting factors
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
0% 50% 100%
Laundries Sector Guide 62
Response to the questionnaire covered 40% of the sites within the laundry sector.
Sector Questionnaire Results
Question 1.a how energy efficient do you see your operation? adequate
Question 1.b is there scope for improvement? Yes
Question 1.c.i.
are there specific areas of your operation which have the
greatest potential for energy saving? Yes
Question 1.c.ii. further detail?
condensing: evap. Water from dryers/ironers; boiler flue gasses;
manager/operator training; switch to gas
Question 1.e
what are the barriers to your organisation becoming more
energy efficient?
Availability of capital and cost of new equipment; attitude to
'production at all costs' without regard to energy efficiency; areas
of use for recovered heat.
Question 1.f.i. what payback period do you accept for energy saving projects? 2-3years
Question 1.f.ii. has this changed over the last 5 years? This time horizon has become stricter
Question 2.a Do you have an Energy Monitoring & Targeting system? Larger sies generally have one, smaller sites don't.
Question 2.b
Have you benchmarked your process against competitors or an
industry standard? 75% of sector have benchmarked their performance
Question 3. current energy efficient technologies available to sector? Average
variable speed drives 52%
energy efficient motors 33%
low temperature washers 58%
product classification, weighing and sorting 75%
renewables 3%
improved process control 27%
use of temperature and/or humidity control within the drying
process 28%
finishing process operated fully loaded/covered 33%
use of VSD compressors 10%
improved burner technology 53%
heat recovery from wash process 62%
heat recovery from drying process 47%
heat recovery from finishing process 2%
adoption of LED lighting 15%
flash steam recovery 62%
hydro-extraction press optimisation 47%
Question 4. potential for CHP Yes for larger sites
restricting factors?
cost/finance; availbility of alternative fuels. "gas can be used to
produce heat at 100% efficiency with condensing flues. If used in
CHP, the gas cannot be used at 100%. Therefore gas CHP is not
the best use of the gas"
Laundries Sector Guide 63
Appendix C: Potential sites for metering
The highlighted sites in the table above are the sites which were selected for the metering programme.
Laundries Sector Guide 64
Appendix D: Installed metering
Item Utility / Product Description Description of requirementsData
Interval
Site Flatw eat 1
1 Gas main Gas meter Existing half hour data from supplier if available( pulse may be available) 2 min
2 Electricity Main Electrical supply Existing half hour data from supplier if available 30 min
3 steam flow new meter to iron1 new 2 inch stem meter to be installed w ith pulsed output. 2 min
4 steam flow new meter to iron2 new 2 inch stem meter to be installed w ith pulsed output. 2 min
5 steam flow existing meter to f lat prod. pulsed output to be connected to metering system 2 min
6 steam flow existing meter to hospital prod pulsed output to be connected to metering system 2 min
7 gas existing meter to f lat production DOES NOT EXIST
8 gas existing meter to hospital prod pulsed output to be connected to metering system 2 min
9 electricity iron1 new nemo modbus electricity meter to be installed w ith CT-s 2 min
10 electricity iron2 new nemo modbus electricity meter to be installed w ith CT-s 2 min
11 humidity iron1 new relative humidity sensor to be f itted 0-100% RH = 4-20ma 2 min
12 temp iron1 new temp sensor f itted to exhaust duct range 0-100C = 4-20ma 2 min
13 exhaust f low iron1 MANNUAL PROBE TO GAIN DATA READINGS
14 humidity iron2 new relative humidity sensor to be f itted 0-100% RH = 4-20ma 2 min
15 temp iron2 new temp sensor f itted to exhaust duct range 0-100C = 4-20ma 2 min
16 exhaust f low iron2 MANNUAL PROBE TO GAIN DATA READINGS
Site Flatw ear 2
1 gas consumption Main Gas meter Existing half hour data from supplier if available( pulse available) 2 min
2 electricity consumption Main Electricity Meter Existing half hour data from supplier if available 30 min
3 electricity consumption "Trans 1" (CBW) new nemo electricity meter 2 min
4 steam flow "Trans 1" (CBW) DOES NOT EXIST
5 flash steam flow "Trans 1" (CBW) new 2 inch steam meter 2 min
6 w ater f low "Trans 1" (CBW) new 2 inch w ater meter 2 min
7 Trans1 w ater temperature in "Trans 1" (CBW) new temperature sensor 2 min
8 Trans2 w ater temperature out "Trans 1" (CBW) new temperature sensor 2 min
9 Trans1 press pressure "Trans 1" (CBW) Press new pressure transducer 2 min
10 Trans1 press Electricity "Trans 1" (CBW) Electricity 2 min
11 Trans1 press membrane pressure "Trans 1" (CBW) Press new pressure transducer 2 min
12 Steam flow machine 2 Machine 2 2 min
13 Steam flow machine 1 & 2 Machine 1 & 2 2 min
Site Workw ear 1
1 Main Gas Consumption main Gas meter Existing half hour data from supplier if available( pulse may be available)
2 Main Electricity Consumption Main Electrical supply Existing half hour data from supplier if available
Appendix E: Schedule of headline engagement activities
Sector Workshop 1: Building the Collaboration and Identifying Key Suppliers.
This was an initial project meeting to engage the laundry sector through the Textile Services Association (TSA).
Prior to this meeting we provided background information on the project and the benefits it will bring to the sector.
We also spoke to the larger companies on a one to one basis to ensure they were fully engaged in the project
and used these meetings to progress the selection of the pilot sites with the TSA and the major laundry
companies. We had excellent commitment from the TSA to organising the workshops and using them to build a
collaborative response to the challenge of reducing CO2 emissions within the sector.
Date Engagement Activity Description
Sector kick off meeting plan interaction and identify key players.
Carbon Trust kick off meeting Develop plan, milestones and confirm project scope.
Data collection from sector Use site specific data to help gain initial understanding of process and sector
Ju
l-1
0 Discussion with TSA and sites Identification of suppliers and possible sites to be metered
Au
g-1
0 Laundry visits To assess potential to become a metered site and to understand process
Workshop 1 Workshop to engage with the sector and to identify key suppliers to be brought
into the programme
Laundry visits To assess potential to become a metering site and to understand process
Upper quartile laundry visits To understand large scale laundry process and gather views on potential and
ideas. Get site input for any suppliers which should be approached.
Oct-
10 Supplier visit Site visit with chemical supplier to understand their role and potential impact.
Workshop 2 Identifying opportunities that could deliver the step change
New Supplier Identification Following up recommendations from sites as to suppliers who should be
involved
Supplier telephone discussion Discussion with suppliers of input required
Visits to small/medium sized laundry
Presentation at NLG meeting Build engagement and gather views and input from smaller sized laundries
Site visits to small/medium sized laundries Understand process in a smaller laundry and gain their perspective and input
into the programme
Telephone discussion with non sector equipment suppliers discussions with non-laundry sector suppliers to allow different technologies
and ideas to be developed.
Telephone discussions with a variety of different sized
workwear and flatwear sites with non sector equipment
suppliers
Gather sector view and input into the programme, to help understand adoption of
best practice.
Supplier discussion Discussion with suppliers to explore possible projects they could bring to the
programme
Workshop 3 To decide on the opportunities that should be recommended for further
investigation.
Sector questionnaire Sent out to get a broad view on best practice and sector view on energy
efficiency
Ma
r-1
1S
ep
-10
No
v-1
0D
ec-1
0J
an
-11
Feb
-11
Ju
n-1
0
Laundries Sector Guide 66
Sector Workshop 2: Opportunity Identification.
This sector workshop focussed on identifying technologies that have the potential to deliver a step change in the
carbon performance of the sector, this was done using the accelerator criteria to avoid concentrating on
technologies already adequately covered by the Carbon Trust in other programmes or that are already widely
deployed. The event had four main aims:
a) To brainstorm for energy efficiency ideas
b) To map the ideas onto process diagrams and energy balances of laundry processes to make an initial determination of their impact
c) To identify generic barriers to the development and adoption of innovations
d) To identify the development resources available to the sector, e.g. equipment manufacturers, cleaning product suppliers, Universities, etc.
A series of visits and phone calls were made to a number of laundry operators and suppliers who could not
attend the meeting to ensure we had a broad and representative view of the laundry sector.
Subsequently a list of potential opportunities was circulated to all attendees through the TSA and updated as
other ideas were uncovered through the life of the project. These opportunities formed the basis of workshop 3.
Sector Workshop 3: Project Recommendations.
A third workshop was arranged through the TSA to consult on the final recommendations and the barriers to their
development and adoption. The objectives of this workshop were to:
Present the insights the project has given into the energy efficiency of the laundry processes; using speakers
from host sites to make contributions
Present the prioritised list of the key opportunities and receive feedback on our recommendations for
development
Establish a consensus on the three to five recommended opportunities for Phase 2 of the accelerator
Highlight the barriers to the technologies being adopted and discuss possible solutions.
Laundries Sector Guide 67
Appendix F: Monitoring equipment schedule
Site Equipment Metered Parameter Comments
Flat Wear
Laundry 1
Main site utility supplies Electricity & gas Historic readings only
Utility sub meters (limited main
areas)
Gas & steam
Ironers *2 Steam Good data
Electricity Good data
Exhaust vent temperature Good data
Exhaust vent humidity Not operational
Exhaust Flow Spot measurement
Production Good data
Work Wear
Laundry 1 or 2?
Main site utility supplies Electricity & gas Historic readings only
Tunnel finisher Gas Good data
Electricity Good data
Exhaust temperature Good data
Exhaust humidity Good data
Production Reasonable data
Continuous towel washer Steam Not operational
Electricity Good data
Batch washer /extractor Steam Not operational
Electricity Good data
Flat Wear
Laundry 2
Continuous Washing Plant Steam Not operational
Flash steam recovered Not operational
Water supply temperature Good data
Water drain temperature Good data
Extractor press electricity Good data
Extractor press pressure Good data
Laundries Sector Guide 68
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